Mode of casting metal structures in permanent molds having permanent cores.



E. A. OUSTER.

' MODE 0F CASTING METAL STRUCTURES IN PERMANENT MOLDS HAVING PERMANENTUORES.

APPLICATION FILED NOV. 28, 1908.

925,803 Patented June 22, 1909'.

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city of Philadelphia,

UNITED STATES PATENT OFFICE.

EDGAR ALAN CUSTER, OF PHILADELPHIA, PENNSYLVANIA, ASSIGNOR TO THE CUSTERSANDLES S CASTING COMPANY, A CORPORATION OF DELAWARE.

MODE OF CASTING METAL STRUCTURES IN PERMANENT MOLDS HAVING PERMA- NENTCORES.

Specification of Letters Patent.

Patented June 22, 1909.

Application filed November 28, 1908. Serial No. 464,927.

To all whom it may concern:

Be it known that I, EDGAR ALAN CUs'rER, a citizen of the United States,residin at the in the county of Philadelphia and State of Penns lvania,have invented certain new and useful Improvements in the Mode of CastingMetal Structures in Permanent Molds Having Permanent Cores, of which thefollowing is a specification.

My invention has relation to the mode of producing homogeneous caststructures either soft or hard, as required, by the use of permanentmetal cores within permanent metal molds, embracing further developmentsof the art of casting metal structures forming the SIlbjGCt-ll11tt6r ofU. S. Letters Patent No. 870,817, granted to me under date of November12th, 1907, and also embodying salient principles of the application forU. S. Letters Patent filed by me, under date of April 7th, 1908, SerialNo. 425,672, in which basically the invention of that application aswell as the present one, is predicated upon the fact that molten ironwhen allowed to cool sloWl-y separates the carbon into two forms free orgraphitic carbon and combined carbon. The amount of graphitic carbon,present in iron depends upon the rate at which it is cooled. Furthergraphitic carbon, when molten iron is cooled slowly tends to segregatebefore the iron reaches the point at which it sets. -Graphitic carbonforms very quickly and when the iron is cooled the free carbon dividesinto two forms, graphitic and annealing. The difference between the twois simply a difference in form, because both have the same chemicalcharacteristics, thus demonstrating that if molten iron is suddenlychilled to a point at which it sets, the formation of graphitic carbonin the iron is prevented and consequently all or nearly all the carbonexists in a combined state. This is equally true in respect to theaction of sulfur and phosphorus in the iron and consequently segregationof these elements is prevented in the same said manner. The formation ofannealing carbon in iron and of carbid carbon begins after the iron haspassed the setting point and such action can only take place when theiron is permitted to cool normall therefore if molten iron be chilledsudden y from the molten state to the point at which it sets and be thenallowed to cool slowly, at. atmospheric temperature or at an establishedfalling temperature, undesirable actions as the segregation andformation of graphitic carbon are prevented and desirable actions as theformation of annealing carbon and carbid carbon regularly begin. Theseactions produce with certainty a thoroughl homogeneous roduct with suchchange molecular conditions, as to give either a soft or hard or toughresultant product, as desired.

My invention broadly considered, consists in presenting molten iron tothe direct influence of a permanent metal core in a permanent metal moldto change molecular conditions of the metal so as to establishthroughout the homogeneity of the structure cast by the pouring of themolten metal against such a core within the mold to chill quickly orswiftly the molten metal to the point of setting, then removing the coreand opening the mold to remove the structure cast so that the same canthen cool gradually by surrounding atmosphere to thereby derive aresultant homogeneous cast structure throughout.

My present invention will be more fully understood from the accompanyingdrawings illustrating different forms of. means for carrying into effectthe mode of my said invention, in which Figure 1, is a View partly insection and partly in elevation of a two-part permanent metal mold,showing internal formations and a permanent metal core suitablyconnected with a hydraulic or other ram for lifting the core from themold after setting of the structure cast, in this instance a pipe, sothat the mold can then be opened to allow the throughout homogeneousstructure cast to cool by its own annealing heat gradually in thesurrounding atmosphere or in an established falling temperatureaccording to conditions and requirements. Fig. 2, is a similar view, ofa modified form of metal fluid cooled core adapted for use in apermanent mold, Where structures are to be cast with greater thicknessesas to the walls than in the use of a solidmetal core of the type of Fig.1; and Fig. 3, is a transverse sectional view through the permanentmetal mold and metal core on the line :11, m, of Fig. 1.

Referring to the drawings 4, is a permanent two-part metal mold 5, 6, orwhich may be arranged so as to consist of a cope and a 3- Fig. 1, or asingle pourhole 7 to the left in drag depending upon whether occupying avertical or. horizontal position for use. The vertical mold as shown isprovided with either a single pour-hole T, to the right in said Fig. 1,with a series of branches a, b and 0, leading directly to the maincavity 8, of the mold 4, provided with a contracted cylindrical orificeor opening 8", in the base portion as clearly shown in Fig. 1, forescape of gases, etc. The internal mold cavity 8, is so arranged as toreceive a permanent metal cylindri orm core 9, which as shown in Figs. 1and 2, is provided with an enlargement 10,

at one end having an eye 11, to be connected with the piston-rod 12, ofa hydraulic ram or other means 13, for liberating the core whenrequired. The two-part mold 4, in Fig. 1, is arranged in a verticalposition for the casting operation with the gates or pourholes 7 and 7in the top, but a horizontal mold'may be used with equally good results.In such instance, the pour-holes into channelways of the interior of themold 4, will be arranged in substantially the manner shown anddescribedjn U. S. Letters Patents granted to me under the No. 887,070,May 12th, 1908, and No. 898,631, dated September 15th,

In Fig. 2, is shown a thick wall hollow permanent metal core 9*, theinternal chamber 15, of which is provided with a fluid in let pipe 16,extending downwardly thereinto. At the upper end the same is connectedwith a hose or other flexible connection 17, with a fluid supply, notshown. There is also provided a capping 18, having a discharge pipe 19,with a flexible connection 20, to a waste receptacle, not shown- In someinstances, where a heavy or thick wall structure is to be cast, it isdesirable, as practice has demonstrated, to use a fluid cooled metalcore, in a permanent mold 4, to insure the proper establishing of thehomogeneity throughout of the iron in the resultant product by changedmolecular conditions of the metal induced according to the describedmode of my said invention and by quickly chilling the molten metalagainst the core and moldjo the point a of setting of the metal wherebyas practice has established to insure a general character of structurecast which is throughout homogeneous both as to the interior as well asthe exterior.

In connection with the temperature of the molten metal it maybe remarkedthat as it leaves the cupola or other furnace the same will rangebetween 2000 and 2800?:Fah. about and in passing to pouring means, priorto reaching the permanent mold, that temperature is not materiallychanged or modified but the instant the pourings enter the permanentmetal mold and metal core there is eflected a violent or sudden changein the temperature of the molten metalwhich is due to the difi'erence inmaintained temperature between the mold and poured metal, and suchtemperature will range between 1700 and 2200 Fall. as compared to thetemperature thereof as above given in passing from the furnace to thepouring means. This results in preventing through such violent or suddenchilling of the metal to the point of setting of the formation'ofgraphitic carbon in the structure cast,'be-

invention embraces and requires for its ap.

plications, the employment of a permanent metal mold with a permanentcore, solid or fluid cooled, for the making of various kinds or types ofcastings for use, in foundry arts.

Having thus described the nature and objects of my invention, what Iclaim as new and desire to secure by Letters Patent is 1. The mode ofcasting a metal'structure around a permanent core in a permanent moldwhich consists in chilling suddenly molten metal to the point of settingin a structure against the metal core within the permanent mold bychanging molecular conditions of'the metal to thereby establish thehomogeneity of the structure cast, removing the core and structure castfrom the mold so as to cool gradually, substantially as described.

2. The mode of casting a metal structure in around a permanent core in apermanent metal mold, whichconsists in chilling suddenly molten metal tothe point of setting against the metal core within the permanent mold bychanging molecular conditions of the metal to establish throughout thehomogeneity of the structure cast, removing the core and structurecastfrom the mold so as to cool by its own heat in the atmosphere,substantially as described.

3. The mode of casting a metal'structure around a permanent water-cooledcore in a permanent mold, which consists in chilling swiftly moltenmetal to the point of setting about the metal core within the permanentmold to by changing molecular conditions of the metal establishhomogeneity of the structure cast then removin the core and thereafterthe structure cast lromthe mold to cool gradually in the atmosphere,substantially as described. 1

4. The mode of casting a structure around a permanent core within apermanent mold, which consists in swiftly chilling molten metal againstthe metal core confined Within the permanent mold to the point ofsetting, then' removing the metalcore and allowing the structure castupon being freed from its confinement-of the mold to cool in'theatmosphere, substantially as described.

5. The mode of casting a structure around a permanent core within apermanent mold, which consists in suddenly-chilling molten metal againstthe metal core confined under mold, which consists in subjecting moltenmetal at a temperature ranging between 2000 to 2800 Fah. to theinfluence of the core and mold to quickly lower the temperature to from1700 to 2200" Fah. to the point of setting, then removing instantly thecore and then permitting a gradual lowering of the temperature of thestructure by removing. from the mold, substantially as described.

7.- .The'mode of casting metal structures around a permanent core in apermanent mold, which consists in subjecting molten metal at atemperature ranging between 2000 to '2800 Fah. and while holding thecarbon of the molten metal in solution to the direct influence of thepermanent core and mold to thereby quicklyw lower such temperature ofthe metal to between 1700f and 2200 Fah. and while maintaining thecarbon of the metal in a finely divided state to the point'at which themetal assumes form, then removing the core and finally permitting thegradual lowering of the temperature of the structure thereby to providefor the formation of annealing carbon and car- 'bidcarbon therein,substantially as described.

8. The mode of casting metal structures around a permanent core in apermanent mold which consists in chilling suddenly.

molten iron to the point of setting against the core and mold into astructure, then instantly removing the core and cooling gradually atatmospheric temperature to prevent undesirable actions as segregationand formation of graphitic carbon in the structure and to permit ofdesirable actions uniformly as formation of annealing carbon and carbidcarbon therein, substantially as described.

In witness whereof, I have hereunto set my signature in the presence oftwo subscribing witnesses.

EDGAR ALAN (DUSTER.

Witnesses:

J. WALTER DOUGLASS, THOMAS M. SMITH.

